Swarm in Engine

ENGINE INSTRUCTION MANUAL 66 3IRH2N, 3IRH8N, 4IRH8N & 4IRI8N ENGINES

CONTENTS

67 FOREWORD 68 EXTERNAL VIEW : 3IRH2N, 3IRH8N, 4IRH8N & 4IRI8N 69 GENERAL INFORMATION: 3IRH2N, 3IRH8N, 4IRH8N & 4IRI8N Main data and specifications Engine identification Ingersoll–Rand engine after sales support EMISSION CONTROL LABEL 75 FUEL, LUBRICANT, AND COOLANT Fuel Lubricant Coolant 77 OPERATION Check before operation Check and operation after start– up Operation and care of a new engine 81 PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance 87 MAINTENANCE SCHEDULE 88 TROUBLESHOOTING

7/26, 7/31, 7/41, 7/51 67 FOREWORD

The INGERSOLL–RAND industrial diesel engines are a product of long years of experience, advanced technology, and up–to date production facilities. INGERSOLL–RAND takes great pride in the superior durability and operating economy of these engines. In order to get the fullest use and benefit from your engine, it is important that you operate and maintain it correctly. This Manual is designed to help you do this. Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of trouble–free and economical engine operation. Should your engine require servicing, please contact your nearest INGERSOLL–RAND branch or distributor. All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of publication. INGERSOLL–RAND reserves the right to make changes in this Manual at any time without prior notice.

This manual covers both 3 and 4 cylinder naturally aspirated engines. The pictures contained within are for guidance only and might not reflect the physical characteristics of each individual engine covered.

7/26, 7/31, 7/41, 7/51 EXTERNAL VIEWS 68

DIESEL ENGINE Engine External View – Model

1. Lifting eye 14.Fuel filter 2. Cooling water pump 15.Fuel oil inlet 3. Cooling fan 16.Fuel filter mounting with fuel priming pump 4. Crank shaft V–pulley 17.Fuel priming pump 5. V–belt 18.Engine name plate 6. Filler port (engine oil) 19.Air intake port 7. Drain plug (engine oil) 20.Flywheel 8. Fuel injection pump 21.Flywheel housing 3IRH8N, 4IRH8N & 4IRI8N 9. Engine oil cooler (4IRH8N) 22.Starter motor 10.Engine oil filter 23.Exhaust manifold 11.Dipstick (engine oil) 24.Alternator 12.Governor lever 25.Rocker arm cover 13.Intake manifold 26.Filler port (engine oil)

7/26, 7/31, 7/41, 7/51 69 GENERAL INFORMATION

EPA CERTIFIED ENGINE DATA and SPECIFICATIONS Model: 3IRH2N

Engine model name 3IRH2N Engine type Vertical inline water cooled diesel engine Combustion type Direct injection No. of cylinders – bore x stroke. mm 3–82x84 Engine displacement L 1.331 Compression ratio 19.2:1 Firing order 1 – 3 – 2 Exhaust emission control system Fuel injection nozzles, fuel injector pump Governor Mechanical type Injection nozzles Hole type Specified fuel Diesel fuel (ISO 8217 DMA, BS2869 A1/A2) Starter (V–kW) 12–1.2 Alternator (V–A) 12–40 Specified engine oil (API grade) (SAE grade) (CD,CF) (10W–30 or 15W–40) Coolant volume (Engine only) L 1.8 Engine dry weight kg 128 Overall length mm 528 Engine dimensions Overall width mm 489 Overall height mm 565 Valve clearance (cold) mm 0.2 $ 0.05 Nozzle injection pressure MPa 21.6 Injection timing B.T.D.C. at 2.5mm cam lift 18 $1

ENGINE IDENTIFICATION INGERSOLL–RAND ENGINE AFTER SERVICE Serial No Location Please feel free to contact your Ingersoll–Rand dealer for periodical inspection and maintenance. The engine serial number is stamped on engine name plate on top of rocker cover. See illustration on page 68 Ingersoll–Rand Genuine Parts Genuine Ingersoll–Rand parts are identical with those used in the Confirmation of Engine Number engine production, and accordingly, they are warranted by It is advisable to quote the engine serial number together with the Ingersoll–Rand. machine serial number, as it is required when you contact the Genuine Ingersoll–Rand parts are supplied by your Ingersoll–Rand Ingersoll–Rand branch or distributor for repair, service or parts branch or distributor. ordering. Please ensure that only genuine Ingersoll–Rand parts, lubricants and CAUTION: Conduct confirmation of engine serial number with the fluids are used for service and/or repair. engine stopped. To avoid being injured, do not check it, while the engine is still hot.

7/26, 7/31, 7/41, 7/51 GENERAL INFORMATION 70

EPA CERTIFIED ENGINE DATA and SPECIFICATIONS Model: 3IRH8N

Engine model name 3IRH8N Engine type Vertical inline water cooled diesel engine Combustion type Direct injection No. of cylinders – bore x stroke. mm 3–88x90 Engine displacement L 1.642 Compression ratio 19.1:1 Firing order 1 – 3 – 2 Exhaust emission control system Fuel injection nozzles, fuel injector pump Governor Mechanical type Injection nozzles Hole type Specified fuel Diesel fuel (ISO 8217 DMA, BS2869 A1/A2) Starter (V–kW) 12–1.2 Alternator (V–A) 12–40 Specified engine oil (API grade) (SAE grade) (CD,CF) (10W–30 or 15W–40) Coolant volume (Engine only) L 2.0 Engine dry weight kg 155 Overall length mm 564 Engine dimensions Overall width mm 486 Overall height mm 622 Valve clearance (cold) mm 0.2 $ 0.05 Nozzle injection pressure MPa 21.6 Injection timing B.T.D.C. at 2.5mm cam lift 18 $1

7/26, 7/31, 7/41, 7/51 71 GENERAL INFORMATION

EPA CERTIFIED ENGINE DATA and SPECIFICATIONS Model: 4IRH8N

Engine model name 4IRH8N Engine type Vertical inline water cooled diesel engine Combustion type Direct injection No. of cylinders – bore x stroke. mm 88x90 Engine displacement L 2.19 Compression ratio 19:1 Firing order 1 – 3 – 4 – 2 Exhaust emission control system Fuel injection nozzles, fuel injector pump Governor Mechanical type Injection nozzles Hole type Specified fuel Diesel fuel (ISO 8217 DMA, BS2869 A1/A2) Starter (V–kW) 12–1.4 Alternator (V–A) 12–40 Specified engine oil (API grade) (SAE grade) (CD,CF) (10W–30 or 15W–40) Coolant volume (Engine only) L 2.7 Engine dry weight kg 170 Overall length mm 658 Engine dimensions Overall width mm 498.5 Overall height mm 618 Valve clearance (cold) mm 0.2 $ 0.05 Nozzle injection pressure MPa 21.6 Injection timing B.T.D.C. at 2.5mm cam lift 19.5 $1

7/26, 7/31, 7/41, 7/51 GENERAL INFORMATION 72

EPA CERTIFIED ENGINE DATA and SPECIFICATIONS Model: 4IRI8N

Engine model name 4IRI8N Engine type Vertical inline water cooled diesel engine Combustion type Direct injection No. of cylinders – bore x stroke. mm 4–98x110 Engine displacement L 3.319 Compression ratio 18.1:1 Firing order 1 – 3 – 4 – 2 Exhaust emission control system Fuel injection nozzles, fuel injector pump Governor Mechanical type Injection nozzles Hole type Specified fuel Diesel fuel (ISO 8217 DMA, BS2869 A1/A2) Starter (V–kW) 12–2.3 Alternator (V–A) 12–40 Specified engine oil (API grade) (SAE grade) (CD,CF) (10W–30 or 15W–40) Coolant volume (Engine only) L 4.2 Engine dry weight kg 220 Overall length mm 719 Engine dimensions Overall width mm 508 Overall height mm 717 Valve clearance (cold) mm 0.2 $ 0.05 Nozzle injection pressure MPa 21.6 + Injection timing B.T.D.C. at 2.5mm cam lift 15.3 /–1

7/26, 7/31, 7/41, 7/51 73 EMISSION CONTROL LABEL

ENGINE LABEL (FOR EPA) Emission control label is attached on the “top of rocker arm cover.” The location of emission control label attached on the engine may vary depending on the engine specification The following is the sample of a label required for engine emission control information, along with location.

* Engine family name as assigned by EPA and ARB identifying engine family group 3YDXL1.33M3N and this identifies

3 YDX L 1.33 M 3 N Method of air aspiration Number of cylinders Engine speed specifications3*:2003 Displacement (liter)4:2004 Non road / Off–road engine5:2005 Yanmar Diesel *2003 Model year EMISSION CONTROL LABEL 74

4IRL5N EC EMISSION CONTROL LABEL: ENGINE LABEL Emission control label is attached on the “top of the rocker arm cover” The following is the detail of a label required for engine emission control information, along with location.

(97/68/EC Directive label)

Label location:

A. Emission control information label (4IRH8N, 4IRI8N) B. Emission control information label (On rocker arm cover exhaust 74side) (3IRH2N, 3IRH8N)

7/26, 7/31, 7/41, 7/51 75 FUEL, LUBRICANTS, AND COOLANT

FUEL If refueling is done from an oil drum directly, ensure that it has been kept stationary to allow any dust, sediment or water to settle at the Fuel Selection bottom. Do not draw fuel direct from the bottom of the drum to prevent pickup of any settled foreign material. The following properties are required of the diesel fuel. Always fully fill the fuel tank. Drain the sedimented particles in the Must be free from minute dust particles. fuel tank frequently. Must have adequate viscosity.

Must have high cetane value. Water in Fuel

Must have high cetane value., (45 or greater) During refueling, it is possible for water (and other contaminants) to be Must have high fluidity at low temperature. pumped into your fuel tank along with the diesel fuel. This can happen if a fuel provider does not regularly inspect and clean its fuel tanks, or Must have low sulphur content. receives contaminated fuel from its supplier(s). To protect your engine from contaminated fuel, there is a fuel filter system on the engine which Must have little residual carbon. allows you to drain excess water. It is strongly advisable to use ASTM D975 No. 2D (the general automotive diesel engine purpose fuel oil) or equivalent which fully CAUTION: The water/diesel fuel mixture is flammable, and could be meets the above requirements. hot. To avoid personal injury and/or property damage, do not touch the fuel coming from the drain valve, and do not expose the fuel to open flames or sparks. Applicable Standard Recommendation Be sure you do not overfill the fuel tank. Heat (such as from the engine) JIS (Japanese Industrial Standard) K22O4 – 2 can cause the fuel to expand. If the tank is too full, fuel could be forced out. This could lead to a fire and the risk of personal injury and/or DIN (DEUTSCHE INDUSTRIE NORMEN) DIN 51601 equipment damage. SAE (Society of Automotive Engineers) Based NO. 2–D on SAE–J–313C Biocides BS (BRITISH STANDARD) Based on Class A–1 or A–2 In warm or humid weather, fungus and/or bacteria may form in diesel BS/2869–1970 fuel if there is water in the fuel. ISO 8217 DMA NOTICE: Fungus or bacteria can cause fuel system damage by plugging the fuel lines, fuel filters or injector. They can also cause fuel system corrosion. FUEL REQUIREMENTS If fungus or bacteria has caused fuel system problems, you should Notice: the fuel injection pump, injector or other parts of the fuel system have your authorized dealer correct these problems. Then, use a diesel and engine can be damaged if you use any fuel or fuel additive other fuel biocide to sterilize the fuel system (follow the biocide than those specifically recommended by Ingersoll–Rand. manufacturer‘s instructions). Biocides are available from your dealer, service stations, parts stores and other automotive places. See your NOTE: If any fuel other than the one specified is used, engine operation authorized dealer for advice on using biocides in your area and for will be impaired. Engine failure or malfunction resulting from use of such recommendations on which biocides you should use. improper fuel will not be warranted by Ingersoll–Rand.

To help avoid fuel system or engine damage, please read the following: Smoke Suppressants The use of a smoke suppressant additive is not allowed because of the Do not use diesel fuel which has been contaminated with engine oil. greater possibility of stuck rings and valve failure, resulting from Besides causing engine damage, such fuel can also affect emission control. Before using any diesel fuel, check with the fuel supplier to see excessive ash deposits. if the fuel has been mixed with engine oil.

Your engine is designed to use either Number 1–D or Number 2–D diesel fuel. However, for better fuel economy, use Number 2–D diesel fuel whenever possible. At temperatures less than –7C, (20F), Number 2–D fuel may pose operating problems (see “Cold Weather Operation” which follows). At colder temperatures, use Number 1–D fuel (if available) or use a “winterized” Number 2–D (a blend of Number 1–D and Number 2–D). This blended fuel is usually called Number 2–D also, but can be used in colder temperatures than Number 2–D fuel which has not been “winterized.” Check with the fuel supplier to be sure you get the properly blended fuel.

NOTICE: Do not use home heating oil or gasoline in your diesel engine; either may cause engine damage.

Handling of the Fuel. Any fuel containing dust particles or water might cause engine failure . Therefore, the following must be observed. Take care to protect the fuel from ingress of dust particles or water when filling the fuel tank.

7/26, 7/31, 7/41, 7/51 FUEL, LUBRICANTS, AND COOLANT 76

LUBRICANT. NOTE The quality of engine oil can affect engine performance, startability Using a mixture of different brands or quality of oils will adversely affect and engine life. the original oil quality; therefore, never mix different brand or different type oils. Use of unsuitable engine oil will result in piston ring, piston and cylinder seizure and accelerate surface wear causing increased oil Do not use API, CA, CB grade and reconstituted engine oil consumption, lowered output and, finally engine failure. To avoid this, Engine damage due to improper maintenance, or using oil of the use the specified engine oil. improper quality and/or viscosity, is not covered by the warranty. 1) Engine Oil Selection Pro Tec 2) Oil Viscosity Engine oil viscosity affects engine startability, performance, oil consumption, wear and the potential for seizure, etc. Always ensure that lubricants with the correct viscosity for the operating temperature are used. Refer to fig 12.

Fig. 12

A. (Single – grade) IMPORTANT: B. Ambient Temperature • Be sure to add Long Life Coolant Antifreeze (LLC) to soft water. In cold season, the LLC is especially important. Without LLC, cooling C. (Multi – grade) performance will decrease due to scale and rust in the cooling water line. Without LLC, cooling water will freeze and expand to break the cooling line. COOLANT • Be sure to use the mixing ratios specified by the LLC manufacturer All Ingersoll–Rand portable compressor engines are factory filled for your temperature range. with a 50/50 Ethylene glycol base antifreeze/water mix. which provides • protection to –33C (–27F) Do not mix different types (brand) of LLC, chemical reactions may make the LLC useless and engine trouble could result • Replace the cooling water every once a year

CAUTION: When handling Long Life Coolant Antifreeze, wear protective rubber gloves not to contact with it. If contact with the eyes or skin should occur, wash with clean water

7/26, 7/31, 7/41, 7/51 77 OPERATION

ENGINE OPERATION Remove filler cap (yellow coloured) on the rocker arm cover side of engine. Engine Exhaust Gas Caution (Carbon Monoxide) Fill with engine oil up to the upper limit on the dipstick. CAUTION Manually tighten the filler cap. Do not use a tool such as pliers to tighten Do not breathe exhaust gas because it contains carbon monoxide, it. which by itself has no color or odor. Carbon monoxide is a dangerous gas. It can cause unconsciousness and can be lethal. Table of oil pan capacities. Do not run the engine in confined areas (such as garages or next to a building). Keep the exhaust tailpipe area clear of snow and other material to help reduce the buildup of exhaust gases under the Engine oil pan capacity (oil pan) (L) equipment. This is particularly important when parked in blizzard 3IRH2N 5.5 conditions. 3IRH8N 6.7 CHECK BEFORE OPERATION 4IRH8N 7.4 CAUTION: For safety reasons, conduct the inspection with the engine 4IRI8N 10.2 stopped. Engine Oil Level. A certain period of time is required before the engine oil completely Place the engine or the machine on a level surface flows down from the oil filler to the crankcase. Wait at least ten minutes before checking the oil level. Remove the dipstick, wipe it with a cloth. Insert it fully and take it out gently again. NOTE: Take care to avoid engine oil being splashed on the fan drive belt because it causes belt slippage or slackness. Check the oil level against the marks on the dipstick. The oil level must be between the upper level mark and the lower level mark as CAUTION: When adding oil, take care not to spill it. If you spill oil on the illustrated. engine or equipment, wipe it properly, to prevent the risk of fire and personal injury and/or equipment damage.

Fan Belt Check Check the fan belt for tension and abnormalities. When the belt is depressed 7 – 10 mm with the thumb (about 100 N [10 kg] pressure) midway between the fan pulley and alternator pulley, the belt tension is correct. If the belt tension is too high, it will result in alternator failure. A loose belt will cause belt slippage which may result in a damaged belt, abnormal noise, poor battery charging and engine overheating.

Fig. 16

Coolant Level Check The coolant level must be between “MAX COLD” and “MIN” marks on the reserve tank depending on the temperature of the engine. Check and ensure that the level is correct.

CAUTION: When removing the radiator filler cap, while the engine is still hot, cover the cap with cloth, then turn it slowly to gradually release the internal steam pressure. this will prevent anyone from being A. Filler cap scalded by hot steam spurting out from the filler neck. B. Filler port (engine oil) Add coolant mixed to the correct ratio: 50/50 ethylene glycol/water. C. Dipstick D. Upper limit Radiator Cap Condition E. Lower limit After the replenishment of the coolant, install the radiator filler cap. F. Dipstick Make sure the cap is securely installed.

7/26, 7/31, 7/41, 7/51 OPERATION 78

Battery Cable Connection CHECKS AND OPERATION AFTER START–UP

Check the battery cable connections for looseness or corrosion. A Check after the Engine Start–up loosened cable connection will result in hard engine starting or insufficient battery charge. The battery cables must be tightened Check the following items in the engine warming–up operation. securely. Never reverse “+” and “–” terminals when reconnecting cables after disconnection. Even a short period of reverse connection Engine noise and exhaust smoke color – will damage the electrical parts. Listen to the engine and, if any abnormal noise is heard, check to determine the cause. Check the fuel combustion condition by observing the exhaust smoke color. The exhaust smoke color after engine warm–up and at no–load condition should be colorless or light blue. Black or white smoke indicates incorrect combustion. Note: After start–up from cold the engine might be noisier and the exhaust smoke color darker than when it has warmed up. However this condition will disappear after warm up. Leakage in the systems – Check the following items: Fig. 17 Lubrication oil leakage – A Battery cable Check the engine for oil leaks, paying particular attention to oil filter and oil pipe joints. B Connections Fuel leakage – Battery Electrolyte level Check the fuel injection pump, fuel lines and fuel filter for leakage. The amount of electrolyte in the batteries will be reduced after repeated Coolant leakage – Check the radiator and water pump hose discharge and recharge. Check the electrolyte level in the batteries, connections and the water drain cock on the cylinder block for leakage. replenish with a commercially available electrolyte such as distilled water, if necessary. The battery electrolyte level checking procedure Exhaust smoke or gas leakage will vary with battery type. NOTICE: Do not replenish with dilute sulfuric acid in the daily service. Checking coolant level The coolant level could drop because any mixed air is expelled in about CAUTION: 5 minutes after the engine started.

When inspecting the batteries, be sure to stop the engine first. Stop the engine, remove radiator cap, and add coolant. As dilute sulphuric acid is used as electrolyte, be careful not to CAUTION: Hot steam can rush out and you could get burnt if the contaminate your eyes, hands, clothes, and metals with the electrolyte. radiator cap is removed when the engine is hot. Cover the radiator cap If it gets in your eye, wash with a large amount of water at once, then with a thick cloth and loosen the cap slowly to reduce the pressure, then seek medical advice. remove the cap. As highly flammable hydrogen gas is released from the batteries, do not create a spark or allow any naked flame near the batteries.

When handling such metallic articles as tools near the batteries, be sure not to contact the “+” terminal because the compressor body is “–” and a dangerous short circuit might result. When disconnecting the terminals, start with “–” terminal. When connecting them, connect the “–” terminal last.

Fuel level Check the remaining fuel oil level in the fuel tank and re–fuel if necessary.

7/26, 7/31, 7/41, 7/51 79 OPERATION

OPERATION AND CARE OF A NEW ENGINE. Make sure the fan belt is not broken, or off the pulley, and that the fan turns when the engine is started. If the engine coolant level in the Your Ingersoll–Rand engine is carefully tested and adjusted in the reserve tank is low, look for leaks at the radiator hoses and factory, however, further run–in is necessary. Avoid any harsh engine connections, radiator, and water pump. If you find major leaks, do not operation within the initial 100 operating hours. run the engine until these problems have been corrected. If you do not find a leak or other problem, WAIT UNTIL THE ENGINE HAS COOLED Do not operate the unit at full load until the engine is warmed–up. DOWN then carefully add engine coolant to the reserve tank. Do not allow the engine to run unloaded for extended periods so as to (Engine coolant is a mixture of ethylene glycol antifreeze and water. minimise the risk of cylinder bore glazing. See “Engine Care in cold season” for the proper antifreeze and During operation, pay attention to the following points if the engine mixture.) shows any sign of abnormalities. CAUTION: To avoid being burned, do not spill antifreeze or engine (1) Engine Oil Pressure – The engine oil pressure is monitored by a coolant on the exhaust system or hot engine parts. Under some switch that will stop the engine if the pressure falls below a pre–set conditions the ethylene glycol in engine coolant is combustible. value. If the engine coolant level in the reserve tank is at the correct level but (2) Coolant Temperature – The engine performance will be adversely there is still an indication of an overheat condition and no cause was affected if engine coolant temperature is too hot or too cold. The normal found, please consult your local Ingersoll–Rand branch or dealer. coolant temperature is 75 to 85C (167 to 185F). Overcooling Overheating Operating the engine at low coolant temperature will not only increase the oil and fuel consumption but also will lead to premature parts wear CAUTION: which may result in engine failure. Ensure that the engine reaches If you see or hear escaping steam or have other reason to suspect normal operating temperature 75 to 85C (167 to 185F) within ten there is a serious overheat condition, stop the engine immediately. minutes of starting. If the Engine Coolant Temperature gage (where fitted) shows an (3) Hourmeter overheat condition, or you have reason to suspect the engine may be This meter indicates the machine operation hours. Make sure that the overheating, take the following step: meter is always working during engine operation. Periodical machine Close the service valve to reduce the load. maintenance is scheduled on the operation hours indicated on the hourmeter. Let the engine run at normal idle speed for two or three minutes. If the engine coolant temperature does not start to drop, turn off the (4) Liquid and Exhaust Smoke Leakage engine and proceed as follows: Make regular checks for lubricant, fuel, coolant and exhaust smoke CAUTION: To help avoid being burned – leakage.

Do not open the canopy or door if you see or hear steam or engine (5) Abnormal Engine Noise coolant escaping. Wait until no steam or engine coolant can be seen or heard before opening the engine canopy or door. In the event of any abnormal engine noise, please consult your local Ingersoll–Rand branch or dealer. Do not remove the radiator filler cap if the engine coolant in the reserve tank is boiling. Also do not remove the radiator filler cap while (6) State of the Exhaust Smoke the engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if either cap is taken off too soon. Check for any abnormal exhaust smoke color. If no steam or engine coolant can be seen or heard, open the canopy ENGINE STOPPING or door. If the engine coolant is boiling, wait until it stops before proceeding. The engine coolant level should be between the “MAX (1) Close service valves. COLD” and “MIN” marks on the reserve tank. (2) Before stopping the engine, cool down the engine by operating it at reduced load about three minutes. In this period, check the engine noise for abnormalities.

LONG TERM STORAGE If the equipment is to be out of operation for an extended period, it should be started at least once per week and run on load for about 15 minutes after it has reached normal operating temperature. If this is not possible, Do not drain the cooling water Clean dust or oil from the engine extension Either fill completely or drain the fuel tank Grease accelerator joints and electrical connections Disconnect the negative battery terminal

7/26, 7/31, 7/41, 7/51 ENGINE MAINTENANCE SCHEDULE 80

When performing the following items, the daily inspection items should also be carried out.

IMPORTANT: Establish a periodic check plan according to the operating conditions and make sure to conduct checks at specified intervals. Otherwise, malfunctioning may occur to shorten the engine life. As special knowledge and skill are required for items marked with , consult your local Ingersoll–Rand branch or distributor.

: Check : Replace : Contact your dealer

Periodic inspection interval

System Check item Daily Every 50 Every 250 Every 500 Every Every hours hours hours 1000 2000 hours hours Fuel oil Fuel tank oil level check and refill Draining from fuel tank Draining from oil / water separator Cleaning oil / water separator Fuel filter replacement Engine oil level Engine oil Engine oil replacement 1st time 2nd & Engine oil filter replacement after Check & addition cooling Radiator fin checking & cleaning Cooling fan V–belt checking & adjusting 1st time 2nd & Cooling watewaterr after Cooling water replacement or every 1 yr Cooling water path flushing & maintenance Fuel & cooling water pipe replacement Rubber hoses or every 2 yrs Operating Governor lever & accelerator check & adjust system Intake and Air cleaner element cleaning & replacement exhaust Electrical Battery electrolyte check and recharging equipment Adjust intake I exhaust valve clearance Cylinder head Lapping intake I exhaust valve seats Fuel valve Check fuel injection valve pressure & adjust pump * Check & adjust fuel injection pump

* The specific emissions related parts for the EPA/ARB regulations EPA allows to apply Maintenance schedule for Emission related parts as follows.

– Check Fuel Valve Nozzle and clean Adjust, cleaning and repair of fuel injection Pump and fuel valve nozzle

kW x 130 1500 hours of use and at 1500–hour intervals 3000 hours of use and at 3000–hour intervals thereafter thereafter

7/26, 7/31, 7/41, 7/51 81 PERIODICAL INSPECTION AND MAINTENANCE.

Inspection after initial 50 hours operation (1) Replacing the engine oil and engine oil filter (1st time) When the engine oil is still hot, be careful with a splash of engine oil which may cause burns. Cool the engine to replace engine oil until the engine oil becomes warm. It is most effective to drain the engine oil while the engine is still warm. In early period of use, the engine oil gets dirty rapidly because of the initial wear of internal parts. Replace the engine oil earlier. Engine oil filter should also, be replaced when the engine oil is replaced.

Engine oil and engine oil filter replacing procedures are as follows. Remove the oil filler cap to drain easily while draining the engine oil.

1) Prepare a waste oil container collecting waste oil. 2) Loosen the drain plug using a wrench (customer procured) to drain the engine oil. 3) Securely tighten the drain plug after draining the engine oil. 4) Turn the engine oil filter counter–clockwise using a filter wrench (customer procured) to remove It. 5) Clean the engine oil filter mounting face. The location depends on the engine installed on the machine unit 6) Moisten the new engine oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into A. Dipstick contact with the mounting surface, and tighten it further to 3/4 of a turn B. Oil pan with the filter wrench. C. Drain plug Tightening torque: 19.623.5Nm (2.02.4kgfm)

Applicable engine oil filter Part No. All engines CCN 15897630

7) Fill with the new engine oil until it reaches the specified level as explained in OPERATION section.

IMPORTANT: Do not overfill the oil pan with engine oil. Be sure to keep the specified level between upper and lower limit on the dipstick.

8) Warm up the engine by running for 5 minutes while checking any oil leakage. 9) Stop the engine after warming up and leave it stopping for about 10 minute to recheck the engine oil level with dipstick and replenish the engine oil. If any oil is spilled, wipe it away with a clean cloth.

A. Engine oil filter B. Loosen C. Tighten

7/26, 7/31, 7/41, 7/51 PERIODICAL INSPECTION AND MAINTENANCE. 82

(2) Checking and adjusting cooling fan V–belt ”Used V–belt” refers to a V–belt which has been used on a running engine for 5 minutes or more. When there is not enough tension in the V–belt, the V–belt will slip making it impossible for the alternator to generate power and cooling Install the new V–belt adjusting the deflection to the value in the table water pump and cooling fan will not work causing the engine to below according to the above manner. After adjusting. run the engine overheat. Check and adjust the V–belt tension (deflection) in the for 5 minutes end readjust the deflection to the value in the table above. following manner. 1) Press the V–belt down with your thumb [approx. 98N(10kgf)]. at the middle of the V–belt span to check the tension (deflection). Available positions to check and adjust the V–belt tension (deflection) are at the A, B and C showing with the arrow direction as shown A B C illustration right. 812mm 58mm 711mm You may choose a position whichever you can most easily carry out the check and adjustment on the machine unit. The specified deflection to be measured at each position should be as follows.

A B C 1014mm 710mm 913mm

(Adjusting the V–belt tension)

D. Radiator fan A. Adjust the V–belt tension by prying with a wooden bar E. Set bolt B. Alternator F. Alternator C. Adjusting bracket G. Deflection H. Press with thumb I. Crankshaft V–pulley Use of genuine Ingersoll–Rand fan belt J. V–belt Always use genuine Ingersoll–Rand fan belts as they provide high driving ability and long operating durability. Use of non–Ingersoll–Rand 2) If necessary, adjust the V–belt tension (deflection). To adjust the fan belts could result in premature belt wear or belt elongation leading V–belt tension, loosen the set bolt and move the alternator to tighten the to engine overheating or excessive belt noise. V–belt.

3) Visually check the V–belt for cracks, oiliness or wear. If any , replace the V–belt with new one. CAUTION: “New, V–belt” refers to a V–belt which has been used less than 5 To help avoid being injured, check and adjust the fan belt tension with minutes on a running engine. engine stopped.

7/26, 7/31, 7/41, 7/51 83 PERIODICAL INSPECTION AND MAINTENANCE.

Inspection every 50 hours operation Governor Control Seals (1) Draining of the fuel tank (NOT 7/26) As the governor is precisely adjusted, most of the controls are sealed, please do not break them. Should any adjustment be necessary, 1) Prepare a waste oil container. contact your local Ingersoll–Rand branch or distributor. 2) Remove the drain plug of the fuel tank to drain (water, dust ,etc.) from the fuel tank bottom. NOTE: Ingersoll–Rand will not accept any warranty claim on an 3) Drain until fuel with no water and dust flow out. Then tighten the engine with broken governor seals. drain plug firmly. (3) Inspection of battery (2) Draining of the oil/water separator Fire due to electric short–circuit Draining Water from Fuel Filter/separator. The fuel filter/separator is provided to allow water to be drained from the Make sure to turn off the battery switch or fuel system. Water is heavier than fuel so any water contained in the disconnect the negative cable (–) before system will collect in the bottom of the bowl. inspecting the electrical system. Failure to do so could cause short–circuiting and fires. The clear bowl ‘D’ should be checked on a daily basis and if water is present, it should be drained from the separator. Always disconnect the (–) Negative battery cable first before disconnecting the battery cables Place a suitable container under the separator to prevent any spillage from battery. An accidental “Short circuit” may inside the machine. cause damage, fire and or personnel injury. Slacken the drain valve ‘E’ until water drains from the vent tube. When all the water has been evacuated, tighten the drain valve ‘E’ and And remember to connect the (–) Negative battery cable (back onto the follow the “fuel system air bleeding” procedure below. battery) LAST.

Proper ventilation of the battery area

Keep the area around the battery Well ventilated, paying attention to keep away any fire source. During operation or charging, hydrogen gas is generated from the battery and can be easily ignited.

Do not come in contact with battery electrolyte

Pay sufficient attention to avoid your eyes. or skin from being in contact with the fluid. The battery electrolyte is dilute sulfuric acid and causes burns. Wash it off immediately with a large amount of fresh water if you get any on you.

Clean the battery terminals Fuel System Air Bleeding Check the level of fluid in the battery. The entry of air into the fuel system will cause difficult engine starting When the amount of fluid nears the lower limit, fill with battery fluid or engine malfunction. (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery When carrying out service procedures such as emptying the fuel tank, may overheat and explode. draining the filter/separator, and changing the fuel filter element be sure to bleed air from the fuel system. Battery fluid tends to evaporate more quickly in the summer, and the fluid level should be checked earlier than the specified limes. To activate the “automatic air–bleeding system”, turn the key switch to the “ON” position and energize the electromagnetic pump” to bleed the air.

Air bleeding method: When the “starter switch” is set to the “ON” position to activate the electromagnetic pump, fuel is forced to the fuel valve of each injection pump and then to the leak–off pipe of each injector nozzle, so that any air in the fuel system bleeds off automatically to the fuel tank.

NOTE: Although the fuel system can bleed air automatically when the key switch is in the “ON” position, air can also be manually bled by use of the primer pump facility in the filter/separator assembly. By unscrewing the plastic primer pump head ‘A’ and stroking it up and down, any air bubbles in the system will be purged back to the fuel tank. When this has been completed, the pump head must be screwed back into the filter/separator assembly.

Start the engine and visually check the fuel system for leaks.

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If the engine cranking speed is so slow that the engine does not start Inspection every 250 hours operation up, recharge the battery. (1) Replacing the engine oil and engine oil filter (2nd time and If the engine still will not start after charging, replace the battery. after) Remove the battery from the battery mounting of the machine unit Replace the engine oil every 250 hours operation from 2nd time and on. after daily use if letting the machine unit leave in the place that the Replace the engine oil filter at the same time. Refer to 50 hour ambient temperature could drop at –15C or less. And store the battery inspection, section (1). in a warm place until the next use the unit to start the engine easily at low ambient temperature. (2) Checking and cleaning radiator fins.

Beware of dirt from air blowing

Wear–protective equipment such as goggles to protect your eyes when blowing compressed air. Dust or flying debris can hurt eyes.

Dirt and dust adhering on the radiator fins reduce the cooling performance, causing overheating. Make it a rule to check the radiator fins daily and clean as needed. Blow off dirt and dust from fins and periphery with compressed air [0.19MPa (2kgf/cm2) or less] not to damage the fins with compressed air. If contaminated heavily, apply detergent, thoroughly clean and rinse OPTION with tap water shower.

Follow the instructions an precautions in the manual from the battery maker. A. Battery fluid B. Lower limit C. Upper limit

A. Dust, dirt. B. Radiator fins C. Air blow

IMPORTANT: Never use high pressure water or air from close by fins or never attempt to clean using a wire brush. Radiator fins can be damaged.

7/26, 7/31, 7/41, 7/51 85 PERIODICAL INSPECTION AND MAINTENANCE.

(3) Checking the governor lever and accelerating device. Using a clean cloth, wipe the sealing face of the filter/separator head to ensure correct seating of the sealing ring. The governor lever and accelerating devices (accelerating lever, pedal. etc.) of the machine unit are connected by a fixed linkage to a Fill the element/bowl assembly with clean fuel oil then apply a light coat pneumatic actuator. If the linkage becomes loose, the deviation in the of clean engine oil to the new element seal ring. position may result and make operation unsafe. Check the linkage connections for excess play. For adjustment of linkage see Screw the new element onto the head firmly by hand. compressor operation section. Follow the “fuel system air bleeding” procedure. see “inspection after every 50 hours operation” section 2. Governor Control Seals As the governor is precisely adjusted, most of the controls are sealed, (6) Air cleaner element inspection please do not break them. Should any adjustment be necessary, contact your local Ingersoll–Rand branch or distributor. AIR INTAKE SYSTEM NOTE: Ingersoll–Rand will not accept any warranty claim on an Air cleaner engine with broken governor seals. Engine performance and life vary with the air intake conditions. A dirty air cleaner element reduces the amount of intake air, causing (4) Replacing fuel filter reduced engine output and possible engine damage. Replace the fuel filter at specified intervals before it is clogged with dust Also, a damaged element leads to abrasion of cylinders and valves, to adversely affect the fuel flow. Also, replace the fuel filter after the resulting in increased oil consumption, reduced output and shortened engine has fully been cooled. engine life. 1) Remove the fuel filter using a filter wrench(customer procured). When removing the fuel filter, hold the bottom of the fuel filter with a piece of rag to prevent the fuel oil from dropping. If you spill fuel, wipe INSPECT THE CONDITION OF THE ELEMENT. such spillage carefully. 2) Clean the filter mounting surface and slightly apply fuel oil to the gasket of the new fuel filter. 3) Install the: new fuel filter manually turning until it comes into contact with the mounting surface, and tighten it further to 1/2 at a turn, using a filter wrench. Tightening torque: 11.815.6Nm(1.21.6kgfm)

Applicable fuel filter Part No. All engines CPN 15892747

4) Bleed the fuel system. Refer to section 2 of inspection at 50 hours

IMPORTANT: Be sure to use genuine Yanmar part (super fine mesh filter). Otherwise, it results in engine damage, uneven engine performance and shorter Fig. 32 engine life.

A Normal (5) Changing oil/water separator element. B Clogged C Indicator NOTE: The cartridge and bowl contain fuel. Take care not to spill it during D Red signal disassembly and reassembly. Air cleaner with dust indicator The fuel filter/separator also provides primary filtration and the element This indicator is attached to the air cleaner. When the air cleaner ‘C’ should be changed every 500 operating hours or 6 months, element is clogged, air intake resistance becomes greater and the dust whichever comes first. indicator signal turns to red indicating the element needs to be Change procedure: changed. Unscrew the element ‘C’ from the head taking care not to spill fuel inside When the signal turns to red, replace the element. Then press the dust the machine. Drain any fuel within into a suitable container, then indicator button to reset the indication. unscrew the clear bowl ‘D’ from the element. Discard the old element into a suitable container. (1) Checking and adjusting cooling fan V–belt (2nd time and after) Remove the old ‘O’ ring from the bowl ‘D’ and install the new one Check and adjust the cooling fan V–belt tension every 250 hours supplied with the element. Apply a light coat of clean engine oil to the operation from 2nd time and on. ‘O’ ring and screw the bowl ‘D’ onto the new element ‘C’. See “inspection after initial 50 hours” section (2)

7/26, 7/31, 7/41, 7/51 PERIODICAL INSPECTION AND MAINTENANCE. 86

Inspection every 500 hours operation EPA allows to apply maintenance schedule for emission related parts as follow. (1) Replacing the air cleaner element Replace the air cleaner element periodically even if it is not damaged – Check Fuel Valve Adjust, cleaning and or dirty. When replacing the element, clean the inside air cleaner case Nozzle and clean repair of Fuel injection at the time. If having the air cleaner with double elements, do not Pump and Fuel Valve remove the inner element. If the engine output is still not recover (or the Nozzle. dust indicator still actuates if having the air cleaner with a dust indicator) even though the outer element has replaced with new one, replace the kW x 130 1500 hours of use 3000 hours of use inner element with new one. and at 1500–hour and at 3000–hour intervals thereafter intervals thereafter Inspection every 1000 hours operation (1) Replacing cooling water

Cooling water contaminated with rust or water scale –reduces the cooling effect. Even when antifreeze agent (LLC) is mixed, the cooling water gets contaminated due to deteriorated ingredients. Replace the cooling water at least Once a year. 1) Remove the header tank cap. 2) Remove the bottom radiator hose of the radiator and drain the cooling water. 3) After draining the cooling water, reconnect the hose. 4) Fill radiator and engine with cooling water via the header tank. Beware of scalding by hot water Wait until the temperature goes down before draining the Cooling water. Otherwise, hot water may splash to cause scalding. (2) Checking and adjusting the fuel injection valve As the adjustment requires specialized knowledge and skill, .consult your Ingersoll–Rand dealer. This adjustment is needed to obtain the optimum injection pattern for full engine performance.

(3) Adjusting intake / exhaust valve clearance As this adjustment requires specialized knowledge and skill, consult your Ingersoll–Rand dealer. The adjustment is necessary to maintain the correct timing for the opening and closing of valves. Neglecting the adjustment will cause the engine to run noisily and result in poor engine performance and other damage.

Inspection every 2000 hours operation (1) Flushing the cooling system and checking the cooling system parts As this maintenance requires specialized knowledge and skill, consult your Ingersoll–Rand dealer. Rust and water scale will accumulate in the cooling system through many hours of operation. This lowers the engine cooling effect. And for the engine oil cooler (4TNV98T), they quickly deteriorate the engine oil. Cooling system parts: radiator, cooling water pump, thermostat, cylinder block, cylinder head, oil cooler (4TNV98T). (2) Checking and replacing fuel hoses and cooling water hoses As this maintenance requires specialized knowledge and skill, consult your Ingersoll–Rand dealer. Regularly check the rubber hoses of the fuel system and cooling water system. If cracked or degraded, replace them with new one. Replace the rubber hoses at least every 2 years. (3) Lapping the intake and exhaust valves As this maintenance requires specialized knowledge and skill, consult your Ingersoll–Rand dealer. The adjustment is necessary to maintain proper contact of the valves and seats. (4) Checking and adjusting the fuel injection timing As this maintenance requires specialized knowledge and skill, consult your Ingersoll–Rand dealer.

Checking and adjusting the EPA emission related parts. The inspection and servicing require specialized knowledge and techniques. Consult your Ingersoll–Rand dealer or distributor.

7/26, 7/31, 7/41, 7/51 87 ENGINE MAINTENANCE SCHEDULE

Note: This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion engine useful life. Ingersoll–Rand, however, urges that recommended maintenance service is performed at the indicated intervals.

EXPLANATION OF MAINTENANCE SCHEDULE The following is a brief explanation of the services listed in the preceding Engine Maintenance schedule.

1. Oil level. Check that the oil level is between the max. and the min. level marks. Add oil to the max. level mark if it is below the min. level. If it is above the max. level mark, drain oil until the max. level is reached. 2. Engine oil replacement Change at 500 hours or 6 months, whichever comes first. 3. Oil filter element Change at 500 hours or 6 months, whichever comes first. replacement 4. Fuel leakage Replace any damaged or malfunctioning parts which could cause leakage. 5. Draining water in fuel Drain off water in the fuel filter/separator bowl. filter/separator. 6. Fuel filter element Replace both primary (filter/separator) and secondary elements at 500 hours or 6 months whichever come first. replacement 7. Injection nozzle check Check injection opening pressure and spray condition. (This is a recommended maintenance item ). Consult your local Ingersoll–Rand branch or distributor. 8. Coolant level. Check coolant level and add coolant if necessary. 9. Coolant leakage check Replace any damaged or malfunctioning parts which could cause leakage. 10. Radiator filler cap fitting The radiator cap must be installed tightly and sealing correctly. condition 11. Fan belt tension check Check and adjust fan belt deflection. Look for cracks, fraying and wear. Replace if necessary. 12. Coolant temperature Normal running temperature is 75 to 85C (167 to 185F). Check and repair the cooling system if temperature is abnormal. 13. Coolant replacement Change coolant at intervals of 1000 hours or 12 months, whichever comes first. 14. Radiator external face Check monthly. Clean at intervals of 250 hours or 3 months, whichever comes first. In very dusty environments, cleaning more frequent cleaning might be necessary. 15. Cooling system circuit Clean at intervals of 1000 hours or 12 months, whichever comes first. cleaning 16. Radiator filling cap Check radiator pressure cap periodically for proper operation. Consult your local Ingersoll–Rand branch or function check distributor. 17. Battery electrolyte level Replenish with distilled water if necessary. check 18. Battery cleaning Clean the terminals 19. Battery charge condition If cranking speed is too slow to start the engine, charge the battery. 20. Air filter element Change element at 500 hrs or sooner if the restriction indicator shows red. replacement 21. Cylinder compression Consult your Ingersoll–Rand dealer or distributor pressure 22. Valve clearance check Check and adjust every 1000 hours. Consult your Ingersoll–Rand dealer or distributor

7/26, 7/31, 7/41, 7/51 ENGINE TROUBLESHOOTING 88

This item contains a simple troubleshooting. When a failure takes place on your Ingersoll–Rand engine, diagnose the cause referring this troubleshooting. Should the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearest Ingersoll–Rand engine service outlet.

Engine does not start Battery discharged

Starter does not turn. Bad cable connections.

Starter or starter switch failure.

Safety relay failure.

Engine stop solenoid malfunction.

No fuel in the fuel tank.

No fuel injection. Clogged fuel filter element.

Air in the fuel system.

Starter turns but engine does not Control rack is stuck at no fuel fire. position.

Incorrect preheating operation.

Faulty air heater.

Fuel is injected but engine does not Incorrect injection timing. fire.

Low cylinder compression pressure.

Engine stop solenoid not fully returned.

Engine fires but stalls immediately. Air in the fuel system.

Incorrect low idle speed adjustment.

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Unstable engine running Crack in injection pipe.

Injection nozzle failure.

Unstable low idling Engine stop solenoid return failure.

Uneven compression pressure between cylinders.

Incorrect high idle speed Incorrect control lever adjustment. adjustment.

Governor internal malfunction.

Engine hunting in medium speed Governor spring deteriorated. range.

Air in the fuel system

Insufficient fuel supply. Clogged fuel filter element

Piping failure (squeezed/restricted etc.)

Engine malfunction in high speed Uneven fuel injection amount between cylinders. range.

Deteriorated governor spring.

Incorrect valve clearance adjustment.

Deteriorated valve spring.

Engine speed stuck at high idle. Engine control restriction or seizure.

Engine overheat. Insufficient coolant volume.

Fan belt slippage.

Cooling system defect Thermostat malfunction.

Radiator filler cap malfunction.

Cooling system interior fouled.

Radiator clogged.

Engine over–loaded.

Improper servicing Air cleaner element clogged.

Insufficient airflow/restriction.

Restricted coolant flow (high concentration of antifreeze, etc.)

Low oil pressure Lack of oil Oil leakage

High oil consumption

Wrong oil Wrong type and viscosity.

High coolant temperature. Over heat.

Clogged filter and strainer.

Worn bearings and oil pump.

Faulty relief valve.

7/26, 7/31, 7/41, 7/51 ENGINE TROUBLESHOOTING 90

Low engine output Incorrect injection timing Too far advanced.

Too far retarded.

Injection nozzle malfunction Incorrect injection pressure.

Incorrect spray condition.

Incorrect injection pump adjustment Lack of fuel in tank.

Insufficient fuel supply to the Air in injection pump. injection pump

Fuel filter clogged.

Overflow valve malfunction.

Governor malfunction Incorrect engine control adjustment.

Deteriorated governor spring.

Incorrect valve clearance adjustment.

Cylinder compression leakage Injector nozzle misalignment.

Low cylinder compression pressure Cylinder bore wear.

Insufficient air intake volume. Air cleaner clogged.

Restricted air flow.

Excessive oil consumption Incorrect oil Wrong selection of type and viscosity.

Too much oil quantity.

Engine burning oil Faulty piston rings/damaged cylinder bores.

Faulty valve stem seal.

Damaged seal / Damaged turbocharger seal

Oil leakage Loose joints/gaskets.

Improper installation of filter and piping.

Fuel leakage Damaged seals.

Excessive fuel consumption Improper component installation or tightening.

Excessive injection volume. Injection pump defective.

Excessive mechanical loads

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Improper exhaust Clogged air cleaner.

Damaged injector nozzle.

Excessive black smoke Wrong injector nozzle.

Injection timing incorrect.

Excessive injection volume.

Incorrect fuel.

Water mixing in fuel

Excessive white smoke Low compression pressure.

Injection timing incorrect.

Low coolant temperature

Faulty turbocharger

Battery over discharge Low electrolyte level Crack in battery body.

Natural consumption.

Charging failure Loose or damaged belt.

Faulty alternator.

Damaged wiring or contact failure.

Excessive electrical loads Insufficient battery capacity for the application.

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